US20060115393A1 - Catalytic reactor/heat exchanger reactor - Google Patents
Catalytic reactor/heat exchanger reactor Download PDFInfo
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- US20060115393A1 US20060115393A1 US10/998,852 US99885204A US2006115393A1 US 20060115393 A1 US20060115393 A1 US 20060115393A1 US 99885204 A US99885204 A US 99885204A US 2006115393 A1 US2006115393 A1 US 2006115393A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J19/24—Stationary reactors without moving elements inside
- B01J19/248—Reactors comprising multiple separated flow channels
- B01J19/249—Plate-type reactors
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
- C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
- C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
- C01B3/323—Catalytic reaction of gaseous or liquid organic compounds other than hydrocarbons with gasifying agents
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- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B3/00—Hydrogen; Gaseous mixtures containing hydrogen; Separation of hydrogen from mixtures containing it; Purification of hydrogen
- C01B3/02—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen
- C01B3/32—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air
- C01B3/34—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents
- C01B3/38—Production of hydrogen or of gaseous mixtures containing a substantial proportion of hydrogen by reaction of gaseous or liquid organic compounds with gasifying agents, e.g. water, carbon dioxide, air by reaction of hydrocarbons with gasifying agents using catalysts
- C01B3/382—Multi-step processes
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D9/0031—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other
- F28D9/0043—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other the plates having openings therein for circulation of at least one heat-exchange medium from one conduit to another
- F28D9/005—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits for one heat-exchange medium being formed by paired plates touching each other the plates having openings therein for circulation of at least one heat-exchange medium from one conduit to another the plates having openings therein for both heat-exchange media
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F13/00—Arrangements for modifying heat-transfer, e.g. increasing, decreasing
- F28F13/06—Arrangements for modifying heat-transfer, e.g. increasing, decreasing by affecting the pattern of flow of the heat-exchange media
- F28F13/12—Arrangements for modifying heat-transfer, e.g. increasing, decreasing by affecting the pattern of flow of the heat-exchange media by creating turbulence, e.g. by stirring, by increasing the force of circulation
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/02—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/02—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations
- F28F3/025—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being corrugated, plate-like elements
- F28F3/027—Elements or assemblies thereof with means for increasing heat-transfer area, e.g. with fins, with recesses, with corrugations the means being corrugated, plate-like elements with openings, e.g. louvered corrugated fins; Assemblies of corrugated strips
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F3/00—Plate-like or laminated elements; Assemblies of plate-like or laminated elements
- F28F3/08—Elements constructed for building-up into stacks, e.g. capable of being taken apart for cleaning
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- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2461—Heat exchange aspects
- B01J2219/2462—Heat exchange aspects the reactants being in indirect heat exchange with a non reacting heat exchange medium
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- B01J2219/2469—Feeding means
- B01J2219/247—Feeding means for the reactants
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- B01J2219/2474—Mixing means, e.g. fins or baffles attached to the plates
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- B01J2219/2476—Construction materials
- B01J2219/2477—Construction materials of the catalysts
- B01J2219/2479—Catalysts coated on the surface of plates or inserts
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- B01J2219/24—Stationary reactors without moving elements inside
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- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
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- B01J2219/2491—Other constructional details
- B01J2219/2498—Additional structures inserted in the channels, e.g. plates, catalyst holding meshes
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- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/02—Processes for making hydrogen or synthesis gas
- C01B2203/0205—Processes for making hydrogen or synthesis gas containing a reforming step
- C01B2203/0227—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step
- C01B2203/0244—Processes for making hydrogen or synthesis gas containing a reforming step containing a catalytic reforming step the reforming step being an autothermal reforming step, e.g. secondary reforming processes
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- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/04—Integrated processes for the production of hydrogen or synthesis gas containing a purification step for the hydrogen or the synthesis gas
- C01B2203/0435—Catalytic purification
- C01B2203/044—Selective oxidation of carbon monoxide
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/06—Integration with other chemical processes
- C01B2203/066—Integration with other chemical processes with fuel cells
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- C—CHEMISTRY; METALLURGY
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/08—Methods of heating or cooling
- C01B2203/0805—Methods of heating the process for making hydrogen or synthesis gas
- C01B2203/0838—Methods of heating the process for making hydrogen or synthesis gas by heat exchange with exothermic reactions, other than by combustion of fuel
- C01B2203/0844—Methods of heating the process for making hydrogen or synthesis gas by heat exchange with exothermic reactions, other than by combustion of fuel the non-combustive exothermic reaction being another reforming reaction as defined in groups C01B2203/02 - C01B2203/0294
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
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- C01B2203/0872—Methods of cooling
- C01B2203/0883—Methods of cooling by indirect heat exchange
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/12—Feeding the process for making hydrogen or synthesis gas
- C01B2203/1205—Composition of the feed
- C01B2203/1211—Organic compounds or organic mixtures used in the process for making hydrogen or synthesis gas
- C01B2203/1217—Alcohols
- C01B2203/1223—Methanol
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- C01B2203/12—Feeding the process for making hydrogen or synthesis gas
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- C01B2203/1241—Natural gas or methane
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
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- C01B2203/142—At least two reforming, decomposition or partial oxidation steps in series
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- C01B2203/16—Controlling the process
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- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/16—Controlling the process
- C01B2203/1614—Controlling the temperature
- C01B2203/1623—Adjusting the temperature
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- C01B2203/00—Integrated processes for the production of hydrogen or synthesis gas
- C01B2203/80—Aspect of integrated processes for the production of hydrogen or synthesis gas not covered by groups C01B2203/02 - C01B2203/1695
- C01B2203/82—Several process steps of C01B2203/02 - C01B2203/08 integrated into a single apparatus
Definitions
- This invention relates to catalytic reactor/heat exchanger devices and in more particular applications, to such device as used in fuel processing systems, such as those that produce hydrogen.
- catalytic reactors are common in fuel processing systems or subsystems, such as those that produce hydrogen.
- fuel processing systems or subsystems such as those that produce hydrogen.
- PEM proton exchange membrane
- a fuel such as methanol, methane, or a similar hydrocarbon fuel is converted into a hydrogen-rich stream for the anode side of the fuel cell.
- humidified methanol or natural gas (methane) and air are chemically converted to a hydrogen-rich stream known as reformate by a fuel processing subsystem of the fuel cell system.
- This conversion takes place in a reformer where the hydrogen is catalytically released from the hydrocarbon fuel.
- a common type of reformer is an Auto-thermal Reactor (ATR), which uses air and steam as oxidizing reactants.
- ATR Auto-thermal Reactor
- CO carbon monoxide
- the desired reaction during a selective oxidation process is [2 CO+O 2 ⁇ 2 CO 2 +283 KJ/mol].
- the other competing reactions are a hydrogen oxidation [H 2 +1 ⁇ 2 O 2 ⁇ H 2 O+242 KJ/mol] which converts desired hydrogen gas into water, a reverse water-gas shift [CO 2 +H 2 +41 KJ/mol ⁇ H 2 O+CO] which creates additional harmful CO as well as depleting the amount of hydrogen gas, and methanations [CO+3H 2 ⁇ CH 4 +H 2 O+206 KJ/mol] and [CO 2 +4 H 2 ⁇ CH 4 +2 H 2 O+165 KJ/mol] which also deplete the amount of hydrogen gas in the reformate stream.
- the catalyst and initial temperature are chosen to favor the CO oxidation over the reverse water-gas shift and methanation.
- temperature fluctuations can cause the competing reactions to hinder CO removal performance.
- the optimum temperature for selective oxidation varies depending upon the concentration of carbon monoxide in the reformate. More specifically, the optimum temperature for selective oxidation typically tends to decrease as the concentration of carbon monoxide in the reformate decreases.
- the activity of the catalyst, or the rate at which the desired reaction occurs is a function of the concentration of the reactants (CO and O 2 ) and temperature.
- the CO oxidation reaction, the H 2 oxidation reaction, as well as the methanation reaction are all exothermic, releasing heat as each respective reaction progresses. Therefore, the temperature of the reformate fluid stream can increase as much as 100° C. as it passes through a selective oxidation reactor even if the desired selective oxidation reaction initially dominates. As the temperature increases, the reaction selectivity for CO oxidation decreases with respect to the competing reactions, there-by decreasing overall CO removal efficiency. Thus, it is desirable to remove heat from the reformate flow as it is reacted so as to not lose selectivity of the reaction. However; during low temperature start up conditions, cooling of the reformate fluid stream in the catalytic reaction region can be undesirable because it reduces the already low activity of the catalytic reaction. In fact, it can be advantageous not to cool the reformate during a low temperature start up, because this would allow the catalyst to come up to temperature more quickly.
- a catalytic reactor/heat exchange device for generating a catalytic reaction in a reaction fluid flow and transferring heat to a cooling fluid flow.
- the catalytic reactor/heat exchange device includes a reaction flow inlet, a reaction flow outlet, a set of reaction flow channels extending between the reaction flow inlet to the reaction flow outlet to direct the reaction fluid flow through the device, a set of cooling flow channels interleaved with the reaction flow channels to direct the cooling fluid flow in heat exchange, counterflow relation with the reaction fluid flow, and turbulators in each of the reaction flow channels.
- a selected portion of each of the turbulators includes a catalytic layer to initiate the catalytic reaction at a location spaced downstream from the reaction flow inlet, with the catalytic layer beginning at the location and extending toward the reaction flow outlet.
- An initial portion of each of the turbulators extends from the reaction flow inlet to the location and is free of the catalytic layer to delay the catalytic reaction until the reaction fluid flow reaches the location.
- the selected portion of each of the turbulators is a separate piece from the initial portion of each of the turbulators.
- the selected portion and the initial portion of each of the turbulators are a unitary construction.
- each of the reaction flow channels is bounded by a pair of spaced, generally planar heat transfer surfaces
- each of the turbulators includes a plurality of alternating peaks and valleys joined by wall sections.
- Each of the peaks is adjacent one of the pair of heat transfer surfaces
- each of the valleys is adjacent the other of the pair of heat transfer surfaces.
- each of the selected portions includes a downstream section wherein the wall surfaces are interrupted by louvers having lengths that extend generally parallel to the pair of heat transfer surfaces.
- each of the selected portions includes a downstream section wherein the peaks and valleys are spaced closer to each other than the peaks and valleys of the remainder of the selected portion in a direction transverse to the planes of the pair of heat transfer surfaces and are spaced from the pair of heat transfer surfaces to minimize the transfer of heat from the downstream section to the pair of heat transfer surfaces.
- each of the selected portions includes an upstream section wherein the peaks and valleys are brazed to the pair of heat transfer surfaces, and a downstream section wherein the peaks and valleys are not brazed to the pair of heat transfer surfaces to minimize the transfer of heat from the downstream section to the pair heat transfer surfaces.
- each of the selected portions includes a downstream section wherein the peaks and valleys are removed to minimize the transfer of heat from the downstream section to the pair of heat transfer surfaces.
- the turbulators are lanced-and-offset fins.
- reaction and flow channels are defined by plates located between each of the channels and bars located between each of the plates.
- the flow channels are defined by drawn cup plates located between each of the flow channels with embossment that extend from each of the plates to contact adjacent plates to bound the flow channels.
- each of the flow plates includes a reaction flow inlet opening in fluid communication with the reaction flow inlet, a reaction flow outlet opening in fluid communication with a reaction flow outlet, a cooling flow inlet opening, and a cooling flow outlet opening.
- Each of the reaction flow channels includes a pair of flow directing inserts therein. One of the inserts surrounds an aligned pair of the cooling flow outlet openings and includes a profiled surface extending across the reaction flow channel from an aligned pair of the reaction flow inlet openings to direct the reaction fluid flow therefrom across the reaction flow channel.
- the other of the inserts surrounds an aligned pair of the cooling flow inlet openings and includes a profiled surface extending across the reaction flow channel from an aligned pair of the reaction flow outlet openings to direct the reaction fluid flow across the reaction flow channel to the aligned pair of reaction flow outlet openings.
- Each of the cooling flow channels includes another pair of flow directing inserts therein, with one of the inserts surrounding an aligned pair of the reaction flow outlet openings and including a profiled surface extending across the cooling flow channel from an aligned pair of the cooling flow inlet openings to direct the cooling fluid flow therefrom across the cooling flow channel, and the other of the inserts surrounding an aligned pair of the reaction flow inlet openings and including a profiled surface extending across the cooling flow channel from an aligned pair of the cooling flow outlet openings to direct the cooling fluid flow across the cooling flow channel to the aligned pair of cooling flow outlet openings.
- each of the initial portions occupies about 25% to 50% of the corresponding reaction flow channel. In a further aspect, each of the initial portions occupies about 25% of the corresponding reaction flow channel.
- FIG. 1 is a perspective view of a catalytic reactor/heat exchange device embodying the present invention
- FIG. 2 is an exploded perspective view of the device of FIG. 1 ;
- FIG. 3 is an enlarged, partial perspective view of a turbulator fin that can be used in the device of FIG. 1 ;
- FIG. 4 is an exploded perspective view showing another embodiment of the device of FIG. 1 ;
- FIG. 5 is an exploded perspective view showing yet another embodiment of the device of FIG. 1 ;
- FIG. 6 is a perspective view showing part of a turbulator fin for use in the device of FIG. 5 ;
- FIG. 7 is a partial view taken from line 7 - 7 in FIG. 6 ;
- FIG. 8 is a partial view taken from line 8 - 8 in FIG. 6 ;
- FIG. 9 is a perspective view showing part of another turbulator that can be used in the device of FIG. 5 ;
- FIG. 10 is a partial view taken from line 10 - 10 in FIG. 9 ;
- FIG. 11 is a partial view taken from line 11 - 11 in FIG. 9 ;
- FIG. 12 is a perspective view showing part of another turbulator fin that can be used in the device of FIG. 5 ;
- FIG. 13 is a partial view taken from line 13 - 13 in FIG. 12 ;
- FIG. 14 is a partial view taken from line 14 - 14 in FIG. 12 ;
- FIG. 15 is a partial, exploded, side elevation of another embodiment of the device shown in FIG. 1 ;
- FIG. 16 is a view taken from line 16 - 16 in FIG. 15 ;
- FIG. 17 is a view taken from line 17 - 17 in FIG. 15 ;
- FIG. 18 is a perspective view of another version of a catalytic reactor/heat exchange device embodying the present invention.
- FIG. 19 is a view taken from line 19 - 19 in FIG. 18 .
- a catalytic reactor/heat exchange device 10 embodying the present invention for generating a catalytic reaction in a reaction fluid flow (shown somewhat schematically by arrowed lines 12 ) and transferring heat to a cooling fluid flow (shown somewhat schematically by arrowed lines 14 ).
- a reaction fluid flow shown somewhat schematically by arrowed lines 12
- a cooling fluid flow shown somewhat schematically by arrowed lines 14
- One potential and preferred application for the device 10 is for use as a selective oxidizer in a fuel processing system that produces hydrogen such as was discussed in more detail in the BACKGROUND OF THE INVENTION section of this application.
- the device 10 will find use in any number of other systems that require a catalytic reaction. Accordingly, no limitation to use with a fuel processing system or a fuel cell system is intended unless specifically recited in the claims.
- the device 10 includes a reaction flow inlet 16 , a reaction flow outlet 18 , a set of reaction flow channels 20 (one shown exposed in FIG. 2 ) extending between the inlet 16 and the outlet 18 to direct the reaction fluid flow 12 through the device 10 , a set of cooling flow channels 22 (again one shown exposed in FIG. 2 ) interleaved with the reaction flow channels 20 to direct the cooling fluid flow 14 in heat exchange, counter-flow relation with the reaction fluid flow 12 .
- the cooling flow channels 22 extend between a cooling flow inlet 24 and a cooling flow outlet 26 to direct the cooling fluid flow 14 through the device 10 .
- the device 10 further includes turbulators 30 (shown in the form of a unitary turbulator plate 30 in FIG. 2 ) in each of the reaction flow channels 20 .
- turbulators 30 shown in the form of a unitary turbulator plate 30 in FIG. 2
- One preferred form for the turbulator 30 is shown in partial, perspective view in FIG. 3 in the form of a lanced-and-offset turbulator fin.
- a selected portion 34 of each of the turbulators 30 includes a catalytic layer or coating 36 on the surfaces of the turbulator 30 to initiate the desired catalytic reaction at a location, illustrated by dashed line 38 in FIG. 2 , spaced downstream from the reaction flow inlet 16 .
- the catalytic layer 36 begins at the location 38 and extends towards the reaction flow outlet 18 , and in the embodiment shown in FIG. 2 , extends over the entire remaining length of the turbulator 30 between the location 38 and a trailing edge 39 of the turbulator 30 .
- An initial portion 40 of each 5 of the turbulators 30 extends between the reaction flow inlet 1 6 to the location 38 , preferably from a leading edge 42 of the turbulator 30 to the location 38 , and is free of the catalytic layer 36 to delay the catalytic reaction until the reaction fluid flow 12 reaches the location 38 .
- the reaction fluid flow 12 flowing through the flow channels 20 and the turbulators 30 can be cooled to the optimum temperature range for the desired catalytic reaction by the cooling fluid 14 flowing through the flow channels 22 .
- the initial portions 40 of the turbulators 30 can act as a precooler that provides the reaction fluid flow 12 within the optimum temperature range for the desired catalytic reaction when the reaction fluid flow 12 reaches the location 38 and contacts the catalytic layer 36 , thereby initiating the catalytic reaction. This is desirable in that it can eliminate a separate heat exchanger or precooler that has been required in conventional fuel processing systems.
- the catalytic coating 36 can be applied to the selected portion 34 using any suitable means, either prior to assembly and brazing of the device 10 or after the assembly and brazing of the device 10 .
- a flood-coating process can be used to apply the catalytic coating 36 to the device 10 after brazing.
- this embodiment of the device is formed from a stack 50 of nested, drawn-cup type plates 52 with embossments in the form of edge flanges 54 that extend from each of the plates 52 to contact adjacent plates 52 to bound the flow channels 20 and 22 which are located in alternating fashion between the plates 52 in the stack 50 .
- Each of the plates 52 includes generally planar heat transfer surfaces 56 such that each of the flow channels 20 and 22 is bounded by a spaced pair of the surfaces 56 of adjacent pairs of the plates 52 .
- each of the turbulators 30 includes a plurality of alternating peaks 58 and valleys 60 joined by wall sections 62 .
- Each of the peaks 58 is adjacent one heat transfer surfaces 56 that bound the flow channel 20
- each of the valleys 60 is adjacent the other of the heat transfer surfaces 56 (not shown in FIG. 3 ) that bound the corresponding flow channel 20 .
- the peaks 58 and valleys 60 are bonded, such as by brazing, to their respective heat transfer surfaces 56 to improve the heat transfer thereto.
- lanced-and-offset fins are preferred, in some applications it may be desirable to utilize other suitable turbulators, many of which are known.
- louvered corrugated or serpentine fins can be used, or embossed turbulators can be formed in the planar surfaces 56 .
- suitable heat transfer fins or turbulators 64 may be provided in each of the cooling flow channels 22 to enhance the heat transfer to the cooling flow 14 .
- any suitable heat transfer fin or turbulator may be used as required by the specific parameters of the required application.
- each of the plates 52 includes four flow openings 66 , 68 , 70 , 72 .
- the opening 66 serves as a reaction flow inlet opening
- the opening 68 serves as a reaction flow outlet opening
- the opening 70 serves as a cooling flow inlet opening
- the opening 72 serves as a cooling flow outlet opening, as best seen in FIG. 2 .
- the openings 66 are aligned to define a reaction flow inlet manifold 74 that distributes the reaction fluid flow 12 to each of the flow channels 20 .
- the flow openings 68 are aligned with each other to define a reaction flow outlet manifold 76 that collects the reaction fluid flow 12 from each of the flow channels 20 and directs the reaction fluid flow 12 to the outlet 18 .
- the openings 70 are aligned to define a cooling flow inlet manifold 78 that distributes the cooling fluid flow 14 from the inlet 24 to each of the flow channels 22
- the openings 72 are aligned to define a cooling flow outlet manifold 80 that collects the cooling fluid flow 14 from each of the flow channels 22 and directs the same to the outlet 26 .
- the stack 50 further includes an end plate 52 A that does not include the openings 68 and 70 , but does include the openings 66 and 72 , and another end plate 52 B that does include the openings 68 and 70 and may optionally include the opening 72 if a cooling flow bypass connection 82 is desired for a cooling flow that bypasses the flow channels 22 to combine with the cooling flow 14 in the cooling flow outlet manifold 80 .
- FIGS. 1 and 2 One feature of the embodiment of the device 10 shown in FIGS. 1 and 2 is the provision of a pair of flow directing inserts 90 in each of the flow channels 20 and 22 .
- Each of the inserts 90 surrounds a corresponding pair of the aligned openings 66 , 68 , 70 , or 72 , and includes a profiled surface 92 extending across the associated flow channel 20 or 22 from an opposite, aligned pair of the openings 66 , 68 , 70 or 72 that are open to the corresponding flow channel 20 or 22 .
- the profiled surface 92 serves to direct the corresponding fluid flow 12 or 14 from the opposite, aligned pair of the openings 66 , 68 , 70 or 72 across the corresponding flow channel 20 or 22 in order to get a good distribution of the respective fluid flow 12 or 14 across the corresponding flow channel 20 or 22 .
- the thickness to the inserts 90 corresponds to the thickness of the turbulator 30 or 64 provided in the corresponding flow channel 20 or 22 so that there is good contact between the opposite faces 94 and 96 of each of the inserts and the corresponding heat transfer surfaces 56 that bound the corresponding flow channel 20 or 22 to allow the faces 94 and 96 to be bonded thereto, such as by brazing, in order to prevent leakage from the pair of openings 66 , 68 , 70 or 72 that are surrounded by the insert 90 .
- each of the inserts 90 provides the dual function of sealing one aligned pair of the openings 66 , 68 , 70 or 72 from the corresponding flow channel 20 or 22 while directing the associated fluid flow 12 or 14 into or out of the corresponding flow channel 20 or 22 from or to the corresponding manifold 74 , 76 , 78 or 80 .
- the device 10 further includes a pair of mount flanges 98 fixed to an exterior surface of the plate 52 a to provide mounting points for the device 10 .
- mount flanges 98 are not critical to the invention and any form of mount or mount flange can be used.
- the plates 52 are clad of a suitable brazing alloy so that the components of the device 10 can be brazed as an assembled stack.
- the activity of the catalyst is a function of the concentration of the reactants (CO 2 ) and temperature. The higher the concentration and temperature, the higher the activity. Under normal operating conditions, most of the reactions are completed (and the injected oxygen is used up) in the first 25-40% of the total catalyst length, i.e., the total length of the selected portion 34 , with the remaining downstream portions or sections being essentially inactive. However, when the temperatures in the flow channels 20 are low, such as during start up, the catalyst in the catalytic layer 36 is less active and the downstream portion of the catalyst layer 36 and turbulator 30 become more important in ensuring that the reactions are completed.
- FIG. 4 another embodiment of the device shown in FIG. 1 is shown in an exploded, perspective view, with like reference numbers indicating like features from the previously described embodiment shown in FIG. 2 .
- a pair of identical braze sheets 100 are provided in each of the flow channels 20 on opposite sides of each of the turbulators 30 between the turbulator 30 and each of the associated pair of heat transfer surfaces 56 .
- the braze sheets 100 provide the required braze alloy, rather than having clad braze alloy on the heat transfer surfaces 56 of the plates 52 .
- One or more cutouts 102 (eight shown in FIG.
- each of the braze sheets 100 are provided in each of the braze sheets 100 in order to eliminate any braze alloy between the downstream portions or sections 103 of the turbulator 30 underlying the cutouts 102 and the corresponding heat transfer surface 56 .
- This serves the purpose of eliminating a braze joint between the associated heat transfer surface 56 and each of the sections 103 of the turbulator 30 underlying each of the cutouts 1 02 , thereby reducing the heat conduction between the section 103 of the turbulator 30 and the associated surfaces 56 and minimizing the transfer of heat from the downstream sections 103 of each turbulator 30 to the associated heat transfer surfaces 56 .
- areas equivalent to the cutouts 102 can be created by masking the surfaces 56 with a material (“stop-off”) that prevents braze alloy penetration.
- the embodiment of FIG. 4 also includes modified forms 90 A of the inserts 90 shown in FIG. 2 .
- the inserts 90 A differ from the inserts 90 in that the inserts 90 A including an extension portion 110 that extends outwardly from an edge of the profiled surface 92 .
- the extension 110 includes an opening 112 that is aligned with an associated one of the openings 66 , 68 , 70 or 72 .
- the extension 110 further includes embossed guide vanes or ridges 114 that assist in the distribution of fluid flow across the corresponding flow channel 20 , 22 of the fluid flow exiting the opening 112 .
- the extension 110 also includes a locating edge 116 that abuts the trailing or leading edge 39 , 42 of the associated turbulator 30 , 64 located in the corresponding flow channel 20 , 22 .
- FIG. 5 An exploded view of another embodiment of the device 10 of FIG. 1 is shown in FIG. 5 , again with like reference numbers indicating like components to those previously described in connection with FIGS. 2 and 4 .
- This embodiment is similar to that of FIG. 4 in that it includes at least one downstream section in each of the flow channels 20 wherein the heat transfer performance is intentionally reduced with respect to the remainder of the selected portion 34 .
- the lowered heat transfer performance is achieved by modifying the structure of each of the turbulators 30 in each of the flow channels 20 . More specifically, the down-stream section is defined by one or more sections 120 (eight shown in FIG.
- each of the turbulators 30 wherein the structure of the turbulator 30 has been modified to reduce the heat transfer conduction flow path between the blocks 120 and the corresponding pair of surfaces 56 .
- This reduction can be achieved in at least one of three ways, with one way described and shown in connection with FIGS. 6-8 , another way described and shown in connection with FIGS. 9-11 , and a third way shown in connection with FIGS. 12-14 .
- each of the walls 62 of the turbulator structure in the block 120 have been modified by forming a louver 122 therein with lengths that extend parallel (within normal manufacturing tolerances) to the heat transfer surfaces 56 and the plane of the turbulator 30 .
- the louvers 122 serve to minimize the heat conduction flow paths in each of the walls 62 , which in turn reduces the heat transfer from the blocks 120 of the turbulator 30 to the associated pair of heat transfer surfaces 56 .
- FIG. 8 that the remaining turbulator structure 126 in the selected portion 34 is unmodified and accordingly has a higher heat transfer coefficient to each of the surfaces 56 in comparison to the structure in the blocks 120 .
- FIG. 9 shows another embodiment of the turbulator 30 wherein each of the sections 120 is provided by reducing the distance S between the peaks 58 and valleys 60 in each of the sections 120 in comparison to the distance S between the peak 58 and valley 60 of the remainder 126 of the selected portion 34 .
- the peaks 58 and valleys 60 are spaced closer to each other in each of the sections 120 than the peaks 58 and valleys 60 of the remainder of the selected portion 34 in a direction transverse to the planes of the pair of heat transfer surfaces 56 and the turbulator 30 .
- the sections 120 can be formed by spanking or crushing the peaks 58 and valleys 60 in the sections 120 , or by rolling the sections 120 with shorter wall sections 62 .
- FIGS. 12-14 Yet another form of the turbulator 30 of the embodiment of FIG. 5 is shown in FIGS. 12-14 .
- the majority of the peaks 58 and valleys 60 in the downstream section 120 have been removed from the turbulator 30 , with only occasional ones 58 A and 60 A being kept intact so as to maintain the structural integrity of the turbulator 30 during assembly.
- the removal of the peaks 58 and valleys 60 in each of the sections 120 increases the length of the heat transfer conduction flow path between the turbulator structure and the surfaces 56 in the downstream section 120 , thereby reducing the heat transfer in comparison to the remainder 126 of the selected portion 34 which preferably does not have any of its peaks 58 and valleys 60 removed.
- each of the aforementioned embodiments of the turbulator 30 for the embodiment of FIG. 5 include relatively narrow borders 128 that are part of the remainder 126 (i.e., the turbulator structure has not been modified) in order the minimize the expansion of unsupported portions of the surfaces 56 by maintaining the structural integrity of the borders 128 .
- the exact configuration of the borders 128 will be highly dependent upon the particular parameters of each application in order to maintain adequate structural integrity.
- downstream sections 103 , 120 in each of the above described embodiments of FIGS. 4 and 5 are essentially active only during start up when the activity of the upstream catalyst is not sufficient to complete the reactions, minimizing the heat transfer from the downstream sections 103 , 120 has the desirable effect of allowing the downstream sections 103 , 120 including the catalytic layer 36 thereon and the reformate flow 12 passing therethrough, to heat up relatively quickly during start up conditions by retaining much of the heat from the catalytic reactions occurring in the downstream sections 103 , 120 and thereby improving the desired catalytic reaction under start up conditions and particularly under low temperature start up conditions.
- downstream sections 103 , 120 are essentially active only during start up, the reduction of heat transfer performance in the sections 103 , 120 has little effect on normal operation because there is little or no heat generation in the downstream catalytic coating 36 because the reactants, CO and O 2 , have been depleted. While the heat transfer performance of the downstream sections 103 , 120 is poor, the downstream sections 103 , 120 still provide a high surface area for the catalytic coating 36 and good mixing to get the reactants to the catalytic layer 36 during start up.
- FIGS. 1-14 are shown in connection with the drawn-cup type plates 52
- all of the previously described embodiments for the turbulators 30 can also be used in a bar-plate type heat exchanger construction wherein the heat transfer surfaces 56 are provided by flat separator plates 130 and the embossed edge flanges 54 are provided by profiled bars 132 , as best seen in FIGS. 15, 16 and 17 wherein like reference numbers indicate like features. Brazed sheets 134 are provided between the plates 130 and the bars 132 .
- the inserts 90 are no longer used because the profiled bars can provide the required profiled surface 92 as well as the ability to seal the associated openings 66 , 68 , 70 and 72 .
- FIGS. 18 and 19 show another example of a bar-plate construction for the device 10 , again with like numbers indicating like features.
- This embodiment differs from the previously described embodiments in that the bars 132 include interruptions 140 along their longitudinal sides at each of the flow channels 20 to allow insertion of the selected portion of the turbulator 30 , which is provided as a multi-piece construction, rather than a unitary construction.
- a pair of seal flanges 142 are brazed or welded to the bars 132 and include threaded holes 144 and a seal gland groove 146 .
- Each of the flanges 142 receive and mount a cover plate 148 that is held in place by a plurality of bolts 149 that are received in the threaded holes 144 .
- the cover plates can be removed to allow insertion of the selected portion 34 of the multi-piece turbulator 30 .
- the multi-piece turbulator 30 allows for a number of options as follows. First, the catalytic layer 36 on the selected portion 34 can be applied to the selected portion 34 of the assembly after brazing the assembled device 10 . Second, the initial portion 40 of the turbulator 30 can be an entirely different type of turbulator construction, or can have different dimensional parameters than that of the selected portion 34 .
- inlet and outlet sections 150 and 152 can be provided adjacent the respective inlet openings 66 and their respective outlet openings 68 and again can be totally different types of turbulator fins than those of the other portions 34 and 40 , can have different dimensional parameters than the other portions 34 , 40 , or, as shown in FIG. 19 for lanced-and-offset turbulators, can have a completely different orientation that provides a higher inlet pressure drop so as to improve distribution across the flow channel 20 .
- the multi-piece turbulator 30 can allow for a post-cooler section 154 that is downstream from the selected portion 34 so as to further cool the reaction fluid flow after it has undergone the catalytic reaction and before it exits the device 10 , thereby potentially eliminating a need for a heat exchanger downstream from the device 10 .
Abstract
Description
- This invention relates to catalytic reactor/heat exchanger devices and in more particular applications, to such device as used in fuel processing systems, such as those that produce hydrogen.
- There are many known types of catalytic reactors. For example, catalytic reactors are common in fuel processing systems or subsystems, such as those that produce hydrogen. For example, proton exchange membrane (PEM) fuel cell systems will commonly include a fuel processing subsystem that produces hydrogen.
- More specifically, in many PEM fuel cell systems, a fuel such as methanol, methane, or a similar hydrocarbon fuel is converted into a hydrogen-rich stream for the anode side of the fuel cell. In many systems, humidified methanol or natural gas (methane) and air are chemically converted to a hydrogen-rich stream known as reformate by a fuel processing subsystem of the fuel cell system. This conversion takes place in a reformer where the hydrogen is catalytically released from the hydrocarbon fuel. A common type of reformer is an Auto-thermal Reactor (ATR), which uses air and steam as oxidizing reactants. As the hydrogen is liberated, a substantial amount of carbon monoxide (CO) is created which must be reduced to a low level (typically less than 10 ppm) to prevent poisoning of the PEM membrane.
- To reduce the CO concentration to within acceptable levels, several catalytic reactions will generally be used in the fuel processing subsystem to remove CO in the reformate flow. Typical reactions for reduction of CO in the reformate flow include a water-gas shift, as well as a selective oxidation reaction over a precious metal catalyst (with a small amount of air added to the reformate stream to provide oxygen) in a device commonly referred to as a selective oxidizer. Generally, several stages of CO cleanup are required to obtain a reformate stream with an acceptable CO level. Each of the stages of CO cleanup requires the reformate temperature to be reduced to relatively precise temperature ranges so that the desired ca-catalytic reactions will occur and the loading amount of precious metal catalyst can be minimized.
- For example, the desired reaction during a selective oxidation process is [2 CO+O2→2 CO2+283 KJ/mol]. However, there are other competing reactions that are detrimental to the removal of CO from the reformate stream. Specifically, the other competing reactions are a hydrogen oxidation [H2+½ O2→H2O+242 KJ/mol] which converts desired hydrogen gas into water, a reverse water-gas shift [CO2+H2+41 KJ/mol→H2O+CO] which creates additional harmful CO as well as depleting the amount of hydrogen gas, and methanations [CO+3H2→CH4+H2O+206 KJ/mol] and [CO2+4 H2→CH4+2 H2O+165 KJ/mol] which also deplete the amount of hydrogen gas in the reformate stream. The catalyst and initial temperature are chosen to favor the CO oxidation over the reverse water-gas shift and methanation. However, temperature fluctuations can cause the competing reactions to hinder CO removal performance. Furthermore, the optimum temperature for selective oxidation varies depending upon the concentration of carbon monoxide in the reformate. More specifically, the optimum temperature for selective oxidation typically tends to decrease as the concentration of carbon monoxide in the reformate decreases. Additionally, the activity of the catalyst, or the rate at which the desired reaction occurs, is a function of the concentration of the reactants (CO and O2) and temperature.
- The CO oxidation reaction, the H2 oxidation reaction, as well as the methanation reaction are all exothermic, releasing heat as each respective reaction progresses. Therefore, the temperature of the reformate fluid stream can increase as much as 100° C. as it passes through a selective oxidation reactor even if the desired selective oxidation reaction initially dominates. As the temperature increases, the reaction selectivity for CO oxidation decreases with respect to the competing reactions, there-by decreasing overall CO removal efficiency. Thus, it is desirable to remove heat from the reformate flow as it is reacted so as to not lose selectivity of the reaction. However; during low temperature start up conditions, cooling of the reformate fluid stream in the catalytic reaction region can be undesirable because it reduces the already low activity of the catalytic reaction. In fact, it can be advantageous not to cool the reformate during a low temperature start up, because this would allow the catalyst to come up to temperature more quickly.
- It is the primary object of the invention to provide an improved catalytic reactor.
- According to one aspect of the invention, a catalytic reactor/heat exchange device is provided for generating a catalytic reaction in a reaction fluid flow and transferring heat to a cooling fluid flow. The catalytic reactor/heat exchange device includes a reaction flow inlet, a reaction flow outlet, a set of reaction flow channels extending between the reaction flow inlet to the reaction flow outlet to direct the reaction fluid flow through the device, a set of cooling flow channels interleaved with the reaction flow channels to direct the cooling fluid flow in heat exchange, counterflow relation with the reaction fluid flow, and turbulators in each of the reaction flow channels. A selected portion of each of the turbulators includes a catalytic layer to initiate the catalytic reaction at a location spaced downstream from the reaction flow inlet, with the catalytic layer beginning at the location and extending toward the reaction flow outlet. An initial portion of each of the turbulators extends from the reaction flow inlet to the location and is free of the catalytic layer to delay the catalytic reaction until the reaction fluid flow reaches the location.
- In one aspect of the invention, the selected portion of each of the turbulators is a separate piece from the initial portion of each of the turbulators.
- In another aspect, the selected portion and the initial portion of each of the turbulators are a unitary construction.
- In accordance with one aspect, each of the reaction flow channels is bounded by a pair of spaced, generally planar heat transfer surfaces, and each of the turbulators includes a plurality of alternating peaks and valleys joined by wall sections. Each of the peaks is adjacent one of the pair of heat transfer surfaces, and each of the valleys is adjacent the other of the pair of heat transfer surfaces. In a further aspect, each of the selected portions includes a downstream section wherein the wall surfaces are interrupted by louvers having lengths that extend generally parallel to the pair of heat transfer surfaces. In another aspect, each of the selected portions includes a downstream section wherein the peaks and valleys are spaced closer to each other than the peaks and valleys of the remainder of the selected portion in a direction transverse to the planes of the pair of heat transfer surfaces and are spaced from the pair of heat transfer surfaces to minimize the transfer of heat from the downstream section to the pair of heat transfer surfaces. In yet another aspect, each of the selected portions includes an upstream section wherein the peaks and valleys are brazed to the pair of heat transfer surfaces, and a downstream section wherein the peaks and valleys are not brazed to the pair of heat transfer surfaces to minimize the transfer of heat from the downstream section to the pair heat transfer surfaces. According to another aspect, each of the selected portions includes a downstream section wherein the peaks and valleys are removed to minimize the transfer of heat from the downstream section to the pair of heat transfer surfaces.
- In one aspect of the invention, the turbulators are lanced-and-offset fins.
- According to one aspect, the reaction and flow channels are defined by plates located between each of the channels and bars located between each of the plates.
- In one aspect, the flow channels are defined by drawn cup plates located between each of the flow channels with embossment that extend from each of the plates to contact adjacent plates to bound the flow channels.
- In accordance with one aspect, each of the flow plates includes a reaction flow inlet opening in fluid communication with the reaction flow inlet, a reaction flow outlet opening in fluid communication with a reaction flow outlet, a cooling flow inlet opening, and a cooling flow outlet opening. Each of the reaction flow channels includes a pair of flow directing inserts therein. One of the inserts surrounds an aligned pair of the cooling flow outlet openings and includes a profiled surface extending across the reaction flow channel from an aligned pair of the reaction flow inlet openings to direct the reaction fluid flow therefrom across the reaction flow channel. The other of the inserts surrounds an aligned pair of the cooling flow inlet openings and includes a profiled surface extending across the reaction flow channel from an aligned pair of the reaction flow outlet openings to direct the reaction fluid flow across the reaction flow channel to the aligned pair of reaction flow outlet openings. Each of the cooling flow channels includes another pair of flow directing inserts therein, with one of the inserts surrounding an aligned pair of the reaction flow outlet openings and including a profiled surface extending across the cooling flow channel from an aligned pair of the cooling flow inlet openings to direct the cooling fluid flow therefrom across the cooling flow channel, and the other of the inserts surrounding an aligned pair of the reaction flow inlet openings and including a profiled surface extending across the cooling flow channel from an aligned pair of the cooling flow outlet openings to direct the cooling fluid flow across the cooling flow channel to the aligned pair of cooling flow outlet openings.
- According to one aspect of the invention, each of the initial portions occupies about 25% to 50% of the corresponding reaction flow channel. In a further aspect, each of the initial portions occupies about 25% of the corresponding reaction flow channel.
- Other objects, advantages, and aspect of the invention will be apparent from a complete review of the entire specification, including the appended claims and drawings.
-
FIG. 1 is a perspective view of a catalytic reactor/heat exchange device embodying the present invention; -
FIG. 2 is an exploded perspective view of the device ofFIG. 1 ; -
FIG. 3 is an enlarged, partial perspective view of a turbulator fin that can be used in the device ofFIG. 1 ; -
FIG. 4 is an exploded perspective view showing another embodiment of the device ofFIG. 1 ; -
FIG. 5 is an exploded perspective view showing yet another embodiment of the device ofFIG. 1 ; -
FIG. 6 is a perspective view showing part of a turbulator fin for use in the device ofFIG. 5 ; -
FIG. 7 is a partial view taken from line 7-7 inFIG. 6 ; -
FIG. 8 is a partial view taken from line 8-8 inFIG. 6 ; -
FIG. 9 is a perspective view showing part of another turbulator that can be used in the device ofFIG. 5 ; -
FIG. 10 is a partial view taken from line 10-10 inFIG. 9 ; -
FIG. 11 is a partial view taken from line 11-11 inFIG. 9 ; -
FIG. 12 is a perspective view showing part of another turbulator fin that can be used in the device ofFIG. 5 ; -
FIG. 13 is a partial view taken from line 13-13 inFIG. 12 ; -
FIG. 14 is a partial view taken from line 14-14 inFIG. 12 ; -
FIG. 15 is a partial, exploded, side elevation of another embodiment of the device shown inFIG. 1 ; -
FIG. 16 is a view taken from line 16-16 inFIG. 15 ; -
FIG. 17 is a view taken from line 17-17 inFIG. 15 ; -
FIG. 18 is a perspective view of another version of a catalytic reactor/heat exchange device embodying the present invention; and -
FIG. 19 is a view taken from line 19-19 inFIG. 18 . - As seen in
FIGS. 1 and 2 , a catalytic reactor/heat exchange device 10 embodying the present invention is provided for generating a catalytic reaction in a reaction fluid flow (shown somewhat schematically by arrowed lines 12) and transferring heat to a cooling fluid flow (shown somewhat schematically by arrowed lines 14). One potential and preferred application for thedevice 10 is for use as a selective oxidizer in a fuel processing system that produces hydrogen such as was discussed in more detail in the BACKGROUND OF THE INVENTION section of this application. However, it will be appreciated by those skilled in the art that thedevice 10 will find use in any number of other systems that require a catalytic reaction. Accordingly, no limitation to use with a fuel processing system or a fuel cell system is intended unless specifically recited in the claims. - The
device 10 includes areaction flow inlet 16, areaction flow outlet 18, a set of reaction flow channels 20 (one shown exposed inFIG. 2 ) extending between theinlet 16 and theoutlet 18 to direct thereaction fluid flow 12 through thedevice 10, a set of cooling flow channels 22 (again one shown exposed inFIG. 2 ) interleaved with thereaction flow channels 20 to direct the coolingfluid flow 14 in heat exchange, counter-flow relation with thereaction fluid flow 12. Thecooling flow channels 22 extend between a coolingflow inlet 24 and acooling flow outlet 26 to direct the coolingfluid flow 14 through thedevice 10. - The
device 10 further includes turbulators 30 (shown in the form of aunitary turbulator plate 30 inFIG. 2 ) in each of thereaction flow channels 20. One preferred form for theturbulator 30 is shown in partial, perspective view inFIG. 3 in the form of a lanced-and-offset turbulator fin. Returning toFIG. 2 , a selectedportion 34 of each of theturbulators 30 includes a catalytic layer orcoating 36 on the surfaces of theturbulator 30 to initiate the desired catalytic reaction at a location, illustrated by dashedline 38 inFIG. 2 , spaced downstream from thereaction flow inlet 16. Thecatalytic layer 36 begins at thelocation 38 and extends towards thereaction flow outlet 18, and in the embodiment shown inFIG. 2 , extends over the entire remaining length of theturbulator 30 between thelocation 38 and a trailingedge 39 of theturbulator 30. Aninitial portion 40 of each 5 of theturbulators 30 extends between the reaction flow inlet 1 6 to thelocation 38, preferably from a leadingedge 42 of theturbulator 30 to thelocation 38, and is free of thecatalytic layer 36 to delay the catalytic reaction until thereaction fluid flow 12 reaches thelocation 38. It should be appreciated that by providing theinitial portion 40, thereaction fluid flow 12 flowing through theflow channels 20 and theturbulators 30 can be cooled to the optimum temperature range for the desired catalytic reaction by the coolingfluid 14 flowing through theflow channels 22. Thus, theinitial portions 40 of theturbulators 30 can act as a precooler that provides thereaction fluid flow 12 within the optimum temperature range for the desired catalytic reaction when thereaction fluid flow 12 reaches thelocation 38 and contacts thecatalytic layer 36, thereby initiating the catalytic reaction. This is desirable in that it can eliminate a separate heat exchanger or precooler that has been required in conventional fuel processing systems. - The
catalytic coating 36 can be applied to the selectedportion 34 using any suitable means, either prior to assembly and brazing of thedevice 10 or after the assembly and brazing of thedevice 10. For example, a flood-coating process can be used to apply thecatalytic coating 36 to thedevice 10 after brazing. - Turning now to the details of the construction shown in
FIGS. 1 and 2 , it can be seen that this embodiment of the device is formed from astack 50 of nested, drawn-cup type plates 52 with embossments in the form ofedge flanges 54 that extend from each of theplates 52 to contactadjacent plates 52 to bound theflow channels plates 52 in thestack 50. Each of theplates 52 includes generally planar heat transfer surfaces 56 such that each of theflow channels surfaces 56 of adjacent pairs of theplates 52. - With reference to
FIG. 3 , each of theturbulators 30 includes a plurality of alternatingpeaks 58 andvalleys 60 joined bywall sections 62. Each of thepeaks 58 is adjacent one heat transfer surfaces 56 that bound theflow channel 20, and each of thevalleys 60 is adjacent the other of the heat transfer surfaces 56 (not shown inFIG. 3 ) that bound thecorresponding flow channel 20. Preferably, thepeaks 58 andvalleys 60 are bonded, such as by brazing, to their respective heat transfer surfaces 56 to improve the heat transfer thereto. It should be understood that while lanced-and-offset fins are preferred, in some applications it may be desirable to utilize other suitable turbulators, many of which are known. For example, louvered corrugated or serpentine fins can be used, or embossed turbulators can be formed in the planar surfaces 56. - It is also preferred for suitable heat transfer fins or
turbulators 64 to be provided in each of thecooling flow channels 22 to enhance the heat transfer to thecooling flow 14. In this regard, any suitable heat transfer fin or turbulator may be used as required by the specific parameters of the required application. - Turning again to each of the
plates 52, as is common for this type of construction, each of theplates 52 includes fourflow openings opening 66 serves as a reaction flow inlet opening, theopening 68 serves as a reaction flow outlet opening, theopening 70 serves as a cooling flow inlet opening, and theopening 72 serves as a cooling flow outlet opening, as best seen inFIG. 2 . Theopenings 66 are aligned to define a reactionflow inlet manifold 74 that distributes thereaction fluid flow 12 to each of theflow channels 20. Theflow openings 68 are aligned with each other to define a reactionflow outlet manifold 76 that collects thereaction fluid flow 12 from each of theflow channels 20 and directs thereaction fluid flow 12 to theoutlet 18. Theopenings 70 are aligned to define a coolingflow inlet manifold 78 that distributes the coolingfluid flow 14 from theinlet 24 to each of theflow channels 22, and theopenings 72 are aligned to define a coolingflow outlet manifold 80 that collects the coolingfluid flow 14 from each of theflow channels 22 and directs the same to theoutlet 26. - The
stack 50 further includes an end plate 52A that does not include theopenings openings openings opening 72 if a cooling flow bypass connection 82 is desired for a cooling flow that bypasses theflow channels 22 to combine with the coolingflow 14 in the coolingflow outlet manifold 80. - One feature of the embodiment of the
device 10 shown inFIGS. 1 and 2 is the provision of a pair offlow directing inserts 90 in each of theflow channels inserts 90 surrounds a corresponding pair of the alignedopenings surface 92 extending across the associatedflow channel openings corresponding flow channel surface 92 serves to direct thecorresponding fluid flow openings corresponding flow channel respective fluid flow corresponding flow channel inserts 90 corresponds to the thickness of theturbulator corresponding flow channel corresponding flow channel faces openings insert 90. To state this is other words, each of theinserts 90 provides the dual function of sealing one aligned pair of theopenings corresponding flow channel fluid flow corresponding flow channel manifold - The
device 10 further includes a pair ofmount flanges 98 fixed to an exterior surface of the plate 52 a to provide mounting points for thedevice 10. It should be understood that theflanges 98 are not critical to the invention and any form of mount or mount flange can be used. - Preferably, the
plates 52 are clad of a suitable brazing alloy so that the components of thedevice 10 can be brazed as an assembled stack. - As discussed in the BACKGROUND section of the application, the activity of the catalyst, or the rate at which the reaction occurs, is a function of the concentration of the reactants (CO2) and temperature. The higher the concentration and temperature, the higher the activity. Under normal operating conditions, most of the reactions are completed (and the injected oxygen is used up) in the first 25-40% of the total catalyst length, i.e., the total length of the selected
portion 34, with the remaining downstream portions or sections being essentially inactive. However, when the temperatures in theflow channels 20 are low, such as during start up, the catalyst in thecatalytic layer 36 is less active and the downstream portion of thecatalyst layer 36 andturbulator 30 become more important in ensuring that the reactions are completed. In this regard, it would be advantageous to not cool thereformate flow 12 during a cold start up as this would allow theflow channels 20, including thecatalytic layer 36 and thereformate flow 12 to come up to temperature more quickly. On the other hand, also as discussed in the BACKGROUND section, it is important to cool thereformate flow 12 during normal operating conditions so that the catalytic reaction does not lose selectivity. The embodiments shown inFIGS. 4 and 5 are directed towards meeting both of the above-discussed objectives—cooling thereformate flow 12 for normal operation and reduced cooling of thereformate flow 12 for start up. - With reference to
FIG. 4 , another embodiment of the device shown inFIG. 1 is shown in an exploded, perspective view, with like reference numbers indicating like features from the previously described embodiment shown inFIG. 2 . In this embodiment, a pair ofidentical braze sheets 100 are provided in each of theflow channels 20 on opposite sides of each of theturbulators 30 between the turbulator 30 and each of the associated pair of heat transfer surfaces 56. Thebraze sheets 100 provide the required braze alloy, rather than having clad braze alloy on the heat transfer surfaces 56 of theplates 52. One or more cutouts 102 (eight shown inFIG. 4 ) are provided in each of thebraze sheets 100 in order to eliminate any braze alloy between the downstream portions orsections 103 of theturbulator 30 underlying thecutouts 102 and the correspondingheat transfer surface 56. This serves the purpose of eliminating a braze joint between the associatedheat transfer surface 56 and each of thesections 103 of theturbulator 30 underlying each of the cutouts 1 02, thereby reducing the heat conduction between thesection 103 of theturbulator 30 and the associated surfaces 56 and minimizing the transfer of heat from thedownstream sections 103 of each turbulator 30 to the associated heat transfer surfaces 56. - As an alternative to the brazed
sheets 100 withcutouts 102, areas equivalent to thecutouts 102 can be created by masking thesurfaces 56 with a material (“stop-off”) that prevents braze alloy penetration. - As seen in
FIG. 4 , there are eightcutouts 102 which are surrounded by relatively narrow brazedborders 104 in order the minimize the expansion of unsupported portions of thesurfaces 56 by bonding thesurfaces 56 to the portions of theturbulator 30 that underlie theborders 104. The exact configuration of theborders 104 in thedownstream sections 102 will be highly dependent upon the particular parameters of each application, including the internal pressures and the materials selected for theplates 50, in order top maintain adequate structural integrity. - The embodiment of
FIG. 4 also includes modifiedforms 90A of theinserts 90 shown inFIG. 2 . Theinserts 90A differ from theinserts 90 in that theinserts 90A including anextension portion 110 that extends outwardly from an edge of the profiledsurface 92. Theextension 110 includes an opening 112 that is aligned with an associated one of theopenings extension 110 further includes embossed guide vanes orridges 114 that assist in the distribution of fluid flow across thecorresponding flow channel extension 110 also includes a locatingedge 116 that abuts the trailing or leadingedge turbulator corresponding flow channel - An exploded view of another embodiment of the
device 10 ofFIG. 1 is shown inFIG. 5 , again with like reference numbers indicating like components to those previously described in connection withFIGS. 2 and 4 . This embodiment is similar to that ofFIG. 4 in that it includes at least one downstream section in each of theflow channels 20 wherein the heat transfer performance is intentionally reduced with respect to the remainder of the selectedportion 34. In this embodiment, the lowered heat transfer performance is achieved by modifying the structure of each of theturbulators 30 in each of theflow channels 20. More specifically, the down-stream section is defined by one or more sections 120 (eight shown inFIG. 5 ) in each of theturbulators 30 wherein the structure of theturbulator 30 has been modified to reduce the heat transfer conduction flow path between theblocks 120 and the corresponding pair ofsurfaces 56. This reduction can be achieved in at least one of three ways, with one way described and shown in connection withFIGS. 6-8 , another way described and shown in connection withFIGS. 9-11 , and a third way shown in connection withFIGS. 12-14 . - With reference to
FIG. 6 , part of a lanced-and-offsetturbulator 30 is shown in perspective view. As seen inFIGS. 6 and 7 , each of thewalls 62 of the turbulator structure in theblock 120 have been modified by forming alouver 122 therein with lengths that extend parallel (within normal manufacturing tolerances) to the heat transfer surfaces 56 and the plane of theturbulator 30. Thelouvers 122 serve to minimize the heat conduction flow paths in each of thewalls 62, which in turn reduces the heat transfer from theblocks 120 of theturbulator 30 to the associated pair of heat transfer surfaces 56. It can be seen inFIG. 8 that the remainingturbulator structure 126 in the selectedportion 34 is unmodified and accordingly has a higher heat transfer coefficient to each of thesurfaces 56 in comparison to the structure in theblocks 120. -
FIG. 9 shows another embodiment of theturbulator 30 wherein each of thesections 120 is provided by reducing the distance S between thepeaks 58 andvalleys 60 in each of thesections 120 in comparison to the distance S between the peak 58 andvalley 60 of theremainder 126 of the selectedportion 34. To state this in other terms, thepeaks 58 andvalleys 60 are spaced closer to each other in each of thesections 120 than thepeaks 58 andvalleys 60 of the remainder of the selectedportion 34 in a direction transverse to the planes of the pair of heat transfer surfaces 56 and theturbulator 30. This results in thepeaks 58 andvalleys 60 of each of thesections 120 being spaced from the pair of heat transfer surfaces 56 which increases the length of the heat conduction flow path between the turbulator structure in each of thesections 120 and thesurfaces 56 in comparison to theremainder 126 of the selectedportion 34. Thesections 120 can be formed by spanking or crushing thepeaks 58 andvalleys 60 in thesections 120, or by rolling thesections 120 withshorter wall sections 62. - Yet another form of the
turbulator 30 of the embodiment ofFIG. 5 is shown inFIGS. 12-14 . In this embodiment, the majority of thepeaks 58 andvalleys 60 in thedownstream section 120 have been removed from theturbulator 30, with onlyoccasional ones turbulator 30 during assembly. The removal of thepeaks 58 andvalleys 60 in each of thesections 120 increases the length of the heat transfer conduction flow path between the turbulator structure and thesurfaces 56 in thedownstream section 120, thereby reducing the heat transfer in comparison to theremainder 126 of the selectedportion 34 which preferably does not have any of itspeaks 58 andvalleys 60 removed. - Similar to the embodiment of
FIG. 4 , each of the aforementioned embodiments of theturbulator 30 for the embodiment ofFIG. 5 include relativelynarrow borders 128 that are part of the remainder 126 (i.e., the turbulator structure has not been modified) in order the minimize the expansion of unsupported portions of thesurfaces 56 by maintaining the structural integrity of theborders 128. Again, as with the embodiment ofFIG. 4 , the exact configuration of theborders 128 will be highly dependent upon the particular parameters of each application in order to maintain adequate structural integrity. - Because the
downstream sections FIGS. 4 and 5 are essentially active only during start up when the activity of the upstream catalyst is not sufficient to complete the reactions, minimizing the heat transfer from thedownstream sections downstream sections catalytic layer 36 thereon and thereformate flow 12 passing therethrough, to heat up relatively quickly during start up conditions by retaining much of the heat from the catalytic reactions occurring in thedownstream sections downstream sections sections catalytic coating 36 because the reactants, CO and O2, have been depleted. While the heat transfer performance of thedownstream sections downstream sections catalytic coating 36 and good mixing to get the reactants to thecatalytic layer 36 during start up. - While the embodiments illustrated in
FIGS. 1-14 are shown in connection with the drawn-cup type plates 52, all of the previously described embodiments for theturbulators 30 can also be used in a bar-plate type heat exchanger construction wherein the heat transfer surfaces 56 are provided byflat separator plates 130 and theembossed edge flanges 54 are provided by profiledbars 132, as best seen inFIGS. 15, 16 and 17 wherein like reference numbers indicate like features.Brazed sheets 134 are provided between theplates 130 and thebars 132. One additional difference between the previously described embodiments and that shown inFIGS. 15-17 is that theinserts 90 are no longer used because the profiled bars can provide the required profiledsurface 92 as well as the ability to seal the associatedopenings -
FIGS. 18 and 19 show another example of a bar-plate construction for thedevice 10, again with like numbers indicating like features. This embodiment differs from the previously described embodiments in that thebars 132 includeinterruptions 140 along their longitudinal sides at each of theflow channels 20 to allow insertion of the selected portion of theturbulator 30, which is provided as a multi-piece construction, rather than a unitary construction. In this regard, a pair ofseal flanges 142 are brazed or welded to thebars 132 and include threadedholes 144 and aseal gland groove 146. Each of theflanges 142 receive and mount acover plate 148 that is held in place by a plurality ofbolts 149 that are received in the threaded holes 144. The cover plates can be removed to allow insertion of the selectedportion 34 of themulti-piece turbulator 30. Themulti-piece turbulator 30 allows for a number of options as follows. First, thecatalytic layer 36 on the selectedportion 34 can be applied to the selectedportion 34 of the assembly after brazing the assembleddevice 10. Second, theinitial portion 40 of theturbulator 30 can be an entirely different type of turbulator construction, or can have different dimensional parameters than that of the selectedportion 34. Furthermore, inlet andoutlet sections 150 and 152 can be provided adjacent therespective inlet openings 66 and theirrespective outlet openings 68 and again can be totally different types of turbulator fins than those of theother portions other portions FIG. 19 for lanced-and-offset turbulators, can have a completely different orientation that provides a higher inlet pressure drop so as to improve distribution across theflow channel 20. Finally, themulti-piece turbulator 30 can allow for apost-cooler section 154 that is downstream from the selectedportion 34 so as to further cool the reaction fluid flow after it has undergone the catalytic reaction and before it exits thedevice 10, thereby potentially eliminating a need for a heat exchanger downstream from thedevice 10.
Claims (16)
Priority Applications (9)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/998,852 US7618598B2 (en) | 2004-11-29 | 2004-11-29 | Catalytic reactor/heat exchanger |
DE102005054713A DE102005054713A1 (en) | 2004-11-29 | 2005-11-17 | Heat exchanger device |
AU2005237112A AU2005237112A1 (en) | 2004-11-29 | 2005-11-23 | Catalytic reactor/heat exchanger |
CA002527932A CA2527932A1 (en) | 2004-11-29 | 2005-11-25 | Catalytic reactor/heat exchanger |
FR0511960A FR2878517A1 (en) | 2004-11-29 | 2005-11-25 | Catalytic reactor and heat exchange device for use in fuel processing system, has portion of turbulator, which is free of catalytic layer to delay catalytic reaction until reaction fluid reaches location spaced downstream from inlet |
JP2005342112A JP4750542B2 (en) | 2004-11-29 | 2005-11-28 | Catalytic reactor / heat exchanger |
RU2005136995/15A RU2005136995A (en) | 2004-11-29 | 2005-11-28 | CATALYTIC REACTOR / HEAT EXCHANGE DEVICE |
KR1020050114866A KR20060059840A (en) | 2004-11-29 | 2005-11-29 | Catalytic reactor/heat exchanger |
BRPI0504838-9A BRPI0504838A (en) | 2004-11-29 | 2005-11-29 | catalytic heat exchanger / reactor |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/998,852 US7618598B2 (en) | 2004-11-29 | 2004-11-29 | Catalytic reactor/heat exchanger |
Publications (2)
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US20060115393A1 true US20060115393A1 (en) | 2006-06-01 |
US7618598B2 US7618598B2 (en) | 2009-11-17 |
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Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/998,852 Expired - Fee Related US7618598B2 (en) | 2004-11-29 | 2004-11-29 | Catalytic reactor/heat exchanger |
Country Status (9)
Country | Link |
---|---|
US (1) | US7618598B2 (en) |
JP (1) | JP4750542B2 (en) |
KR (1) | KR20060059840A (en) |
AU (1) | AU2005237112A1 (en) |
BR (1) | BRPI0504838A (en) |
CA (1) | CA2527932A1 (en) |
DE (1) | DE102005054713A1 (en) |
FR (1) | FR2878517A1 (en) |
RU (1) | RU2005136995A (en) |
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WO2022072183A1 (en) * | 2020-09-30 | 2022-04-07 | Corning Incorporated | Flow reactor with thermal control fluid passage having interchangeable wall structures |
Also Published As
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AU2005237112A1 (en) | 2006-06-15 |
CA2527932A1 (en) | 2006-05-29 |
DE102005054713A1 (en) | 2006-06-08 |
JP2006150355A (en) | 2006-06-15 |
KR20060059840A (en) | 2006-06-02 |
JP4750542B2 (en) | 2011-08-17 |
RU2005136995A (en) | 2007-06-10 |
US7618598B2 (en) | 2009-11-17 |
FR2878517A1 (en) | 2006-06-02 |
BRPI0504838A (en) | 2006-07-11 |
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